Coil assembly for electromechanical transudcer and method for making same

ABSTRACT

The ends of a coiled wire are each connected to a discrete piece of flexible stranded conductor by a discrete malleable connector. The pieces of stranded conductor and discrete malleable connectors comprise severed portions of a single piece of stranded conductor and a single connector, respectively. The malleable connector has an irregular surface for disrupting an insulation coating on the wire or is a laminate with a layer of solder that removes such coating when melted. The method comprises positioning the ends of a coiled wire adjacent to a piece of stranded conductor, forming a connector therearound, and severing the connector, ends of the wire, and stranded conductor to form a pair of separate leads each comprising an end of the coiled wire and a portion of the stranded conductor connected together by a portion of the connector. When the connector is laminate, the step of securing includes heating the connector in order to melt a portion thereof.

United States Patent [72] lnventors Roderick V. Sawyer;

Adrian J. Valsvik, both of Elkhart, Ind.

[21] Appl. No. 761,204

[22] Filed Sept. 20, 1968 [45] Patented June 29, 1971 [73] Assignee CTSCorporation Elkhart, Ind.

[54] COIL ASSEMBLY FOR ELECTROMECHANIC'AL TRANSUDCER AND METHOD FORMAKING SAME 13 Claims, 11 Drawing Figs.

[52] U.S.Cl 179/115.5,

[51] Int. Cl H04r 9/02 [50] FieldofSearch 179/115 5 [56] ReferencesCited UNITED STATES PATENTS 2,037,811 4/1936 McMurtrey et a1. 179/115.52,664,844 1/1954 Siegrist et al. l74/84.1

3,064,072 11/1962 Graffet al ABSTRACT: The ends of a coiled wire areeach connected to a discrete piece of flexible stranded conductor by adiscrete malleable connector. The pieces of stranded conductor anddiscrete malleable connectors comprise severed portions of a singlepiece of stranded conductor and a single connector, respectively. Themalleable connector has an irregular surface for disrupting aninsulation coating on the wire or is a laminate with a layer of solderthat removes such coating when melted. The method comprises positioningthe ends of a coiled wire adjacent to a piece of stranded conductor,forming a connector therearound, and severing the connector, ends of thewire, and stranded conductor to form a pair of separate leads eachcomprising an end of the coiled wire and a portion of the strandedconductor connected together by a portion of the connector. When theconnector is laminate, the step of securing includes heating theconnector in order to melt a portion thereof.

PATENTEDJUNZSIQY: 3590170 SHEET 1 BF 2 FIGURE'S FIGURE- 7 FIGURE-8 IINVENTORS RODERICK V. SAWYER ADRIAN J. VAKSVIK A TORNEY sum 2 [1F 2PATENTEU 29 Ian FIGURE- 9 FIGURE- IO R E S R 0M S m V K l. R E D O RKSV'K TTORNE I FIGURE-ll COIL ASSEMBLY FQR ELECTROMEEIHANKCAL TRANSUDCERAND METHOD FOR MAKING SAME This invention relates generally to coilassemblies and, more particularly, to coil assemblies for use inelectromechanical transducers such as loudspeakers, and to methods formaking same.

A preponderance of all mass produced loudspeakers comprise a magnetstructure, a supporting frame in one form or another, a voice coilmovable with respect to the magnet structure, and a diaphragm supportedby the frame and secured to the voice coil for movement therewith aselectrical signals are applied to the voice coil. The voice coil leadwires invariably are connected to fixed terminals carried on thesupporting frame in order to facilitate connection of the loudspeakerwith apparatus used to supply electrical signals to the loudspeaker.Since voice coil windings and lead wires are usually comprised ofrelatively stiff magnet wire it is desirable, if not necessary, to use aflexible, supple conductor for interconnecting the ends of the voicecoil lead wires and the terminals so that a minimum amount of mechanicalcoupling will exist between the supporting frame and diaphragm.Minimization of such coupling accomplishes the desirable result ofdecreasing the amount ofinterference with movement of the diaphragm andthe amount of distortion in the sound produced by the diaphragm.

Because of the foregoing factors, it is generally standard practice touse a stranded conductor for interconnecting the voice coil lead wireswith the terminals on the speaker frame. Although this practice has beenfollowed for many years, several long recognized problems associatedwith the use of stranded conductors have remained unsolved. The mostimportant of these problems has been the difficulty encountered inconnecting voice coil lead wires to a stranded conductor in an efficientand satisfactory manner without unraveling the strands of material atthe ends of the conductor. Heretofore it has been the usual practice tomanually wrap the ends of the voice coil lead wires around the strandedconductor and then apply molten solder to the connection. The act ofapplying molten solder to the conductor has, in itself, causedadditional problems due to the fact that molten solder and flux, whenheated, will readily flow along the stranded material by capillaryaction. Normally when this occurs, the flexibility of the strandedconductor is destroyed and it is then necessary to remove the solderedstranded conductor from the voice coil lead wire and repeat previouslyperformed operations.

The voice coil lead wires are normally covered with a durable andtenacious insulation coating and heretofore such insulation coating hasbeen removed or otherwise destroyed by the molten solder applied to theconnection. Accordingly, any improved means for making such connectionmust provide for securing a good electrical connection notwithstandingpresence ofinsulation on the voice coil lead wires. When molten solderis used in making such electrical connection it is desirable, if notnecessary, to provide an uncomplicated and economical means that willcounteract the tendency of the molten solder to flow along the strandedconductor by capillary action. On the other hand, if molten solder isnot used in making the connection, other suitable means must be providedthat will disrupt or remove insulation on the lead wires so that asatisfactory connection will be attained. Although various problemsassociated with the manufacture of voice coils for use in loudspeakershave been discussed, similar problems exist in the manufacture of coilassemblies for other devices and, accordingly, the use of the terms coilassemblies and voice coil" in this specification are meant to includecoils that may be used in devices other than loudspeakers.

ln view of the foregoing it will be appreciated that it would bedesirable to provide an improved connection between a voice coil leadwire and a piece of stranded conductive materi al, and an improvedmethod of making same, in order to substantial" rec a'ce the amount oftime and effort involved in making the connection, in order to reducethe number of loudspeakers that are defective because of a faultyconnection between the voice coil lead wires and the strandedconductors, in order to reduce the number of stranded conductors thathave been rendered useless by the flow of solder or flux therealong. andin order to eliminate the unraveling problem associated with the use ofstranded conductive material. It will also be appreciated that theimproved method must provide a good electrical connection even thoughthe voice coil lead wires may be covered with a tenacious insulationcoating.

Accordingly, it is an object of the present invention to pro vide a newand improved loudspeaker having an improved connection between the endsof the voice coil lead wires and pieces of stranded conductive materialinterconnecting the voice coil lead wires to terminals of theloudspeaker.

It is another object of the present invention to provide a new andimproved method for manufacturing a voice coil assembly for anelectromechanical transducer wherein a good electrical connection isattained between insulated voice lead wires and a flexible conductorwithout expending extra time and effort in removing an insulationcoating from the voice coil lead wire prior to making such connection.

A further object of the present invention is to provide an efficient,new, and improved method for connecting conductive material to a pair oflead wires wherein the pair of lead wires are connected together with asingle piece of conductive material and then separated to form a pair ofleads, each comprising one of the lead wires connected to a discreteportion of the piece of conductive material.

Still another object of the present invention is to provide a new andimproved connection between the end of an electromechanical transducercoil lead wire and a piece of conductive material wherein the lead wireand conductive material are held clinched together by a malleableconnector.

A still further object of the present invention is to provide a new andimproved connection between a lead wire and a piece of strandedconductive material wherein the capillary action of a connectorcounteracts the capillary action of the stranded conductive materialwhen a flowable material such as solder is applied thereto.

Briefly, the invention comprises a coil having its ends secured toterminal leads comprising stranded material by means of severed portionsof a discrete connector and a method of making the same. The severedportions of the connector initially are joined together and comprise asingle piece of material. In the method, a pair of coil leads arepositioned adjacent to each other and to a single piece of strandedmaterial. A connector is then tightly clenched around the coil leads andstranded material. Preferably, the connector is a laminate of solder andat least one other malleable material such as brass or a single layer ofmaterial having a serrated surface for disrupting the insulation on thevoice coil lead wires. When either type of material is used, theconnector is tightly formed around the voice coil lead wires and theflexible stranded material to interconnect the flexible strandedmaterial and voice coil lead wires. When a laminate of solder is used,heat applied to the connection, for example by passing a surge ofelectric current therethrough, melts the layer of solder along the innersurface of the malleable material. The solder, upon melting, removes anyinsulation on the voice coil lead wires and provides a good electricalconnection between the flexible stranded material and the voice coillead wires. When the solder flows during this step of the method, theformed malleable connector operates as capillary means and retains thesolder therewithin, thus counteracting the tendency of the solder toflow outwardly from the connector and along the flexible strandedmaterial. The connector is then severed into two pieces to separate thevoice coil lead wires. After being severed, each piece of the connectorcontinues to clinch a piece of flexible stranded material to the end ofone of the voice coil lead wires. Depending on the apparatus used in thepractice of the inventive method and the particular material used as aconnector, the solder portion of the connector may be melted before,after, or substantially at the same time that the connector is severed.After a piece of flexible stranded material has been connected to thevoice coil lead wires, the voice coil is assembled with a frame,diaphragm, and magnet structure, and the free end of the flexiblestranded material is soldered to a terminal carried by the frame tocomplete assembly ofa loudspeaker.

The subject matter which I regard as my invention is set forth in theappended claims. The invention itself, however, together with furtherobjects and advantages thereof may be better understood by referring tothe following description taken in connection with the accompanyingdrawings.

FIG. ll illustrates a voice coil and a piece of flexible strandedconductive material to be connected thereto in accord with theinvention;

FIG. 2 is an isometric view of the voice coil and flexible strandedconductive material of FIG. 1 positioned on an as sembly fixture withthe voice coil lead wires and stranded material positioned adjacent toeach other;

FIGS. 3, 4, and 5 are enlarged cross-sectional views, with parts brokenaway, of the fixture shown in FIG. 2 and schematically illustrate theforming of a malleable connector around the voice coil lead wires andpiece of stranded conductive material;

FIG. 6 is a plan view of the fixture of FIG. 2 with parts broken away,and illustrates a connector formed around the piece of strandedconductive material and voice coil lead wires;

FIGS. 7 and 8 schematically illustrate the steps of severing and heatingthe malleable connector and voice coil lead wires illustrated in FIG. 6;

FIG. 9 is an enlarged isometric view of a voice coil assemblyconstructed in accord with the invention;

FIG. 10 is a cross-sectional view of a loudspeaker embodying theinvention and incorporating the voice coil assembly of FIG. 9; and

FIG. 11 is an enlarged isometric view of another embodiment of amalleable connector that may be used in lieu of the connectorillustrated in FIGS. 3I0 in the practice of the invention.

Now having reference to FIG. 1, there is illustrated therein a voicecoil 10 comprised of a supporting bobbin ll having a plurality of turnsof insulated magnet wire wound thereon. End portions of the magnetwires, herein referred to as voice coil lead wires 12 and 13, projectfrom the bobbin 1).. Positioned adjacent to the voice coil 10 in FIG. Iis a single piece of flexible stranded material or stranded conductor 14having free ends I6, 17. The flexible stranded material is comprised ofa plurality of strands of silver covered copper material and, as will bemore fully explained, the piece of flexible stranded material orstranded conductor 14 is connected along a central portion thereof toboth of the lead wires l2, l3 and then severed along such centralportion. As will be understood from the ensuing disclosure, theconductor 14 does not unravel when severed.

In FIG. 2 there is illustrated a fixture 18 having retaining clips 19,20 supported at either side thereof for holding the stranded conductor14, a connector forming anvil 21, four voice coil lead wire guide pins22, 23, 24, and 26, and a voice coil supporting post 25.

In practice, the stranded conductor 14 is positioned on the anvil 21 andheld in position thereon by the clips 19, 20. The voice coil 10 is thenpositioned on the post and the voice coil lead wire I2 is positionedaround the outside of the pin 26, along the stranded conductor 14, andalong the inside of the pin 23 as best illustrated in FIG. 2. Then thevoice coil lead wire 13 is positioned around the outside of the pin 24,along the stranded conductor 14, and along the inside of the pin 22.When the stranded conductor 14 and voice coil lead wires l2, 13 areproperly positioned on the anvil 21, the stranded conductor I4 iscentered between a pair of longitudinally extending connector-formingshoes 27, 28, as best illustrated in FIG. 3. A laminated malleableconnector 29, held in a movable head of a not shown machine ispositioned above and also centered relative to the pair of shoes 27, 28.The inner layer 31 of the connector 29 is comprised of a malleablematerial having a low melting point such as solder and the outer layer32 of the connector 29 is comprised of a malleable material having arelatively high melting point such as brass. After the voice coil leadwires 12, 13 and stranded conductor 14 have been properly positioned onthe anvil 21, the connector 29 is moved around the juncture of the voicecoil lead wires and stranded conductor, against the anvil 21 and thenformed against the forming shoes 27, 28 to tightly clinch together thevoice coil lead wires and stranded conductor as illustrated in FIGS. 4and 5. As the connector 29 moves into the forming shoes 27, 29, theleading edges of the connector 29 trim away the end portions of thevoice coil lead wires 12, 13 as shown in FIGS. 4-6. With particularreference to FIG. 6, the ends 13a, 12a of the voice coil lead wires 13,12 are trimmed by the connector 29 whereas the remainder of the voicecoil lead wires 12, 13 extend axially into the ends of the connector 29and along the stranded conductor 14. As the connector 29 is formed asshown in FIGS. 5 and 6, a permanent electrical connection is completedbetween the stranded conductor 14 and the voice coil lead wires 13 14even when the voice coil lead wires I3, 14 are covered with a durableand tenacious insulation coating. However, in order to assure that anyinsulation coating on the voice coil lead wires will not interfere withthe making of a good electrical connection and in order to mechanicallyreinforce the connection, it is preferred to heat the connector 29 andvoice coil lead wires 13, 14 and flexible conductor M in order to meltthe inner layer 31 of the connector 29 and substantially simultaneouslydestroy any insulation covering the voice coil lead wires l2, 13 withinthe connector 29 which then serves as a capillary repository for thesolder.

After the connector 29 has been properly formed, the voice coil 10 andstranded conductor 14 are moved to a work station which, as shown inFIGS. 7 and 8, preferably is a combination severing and heating stationequipped with a tool for severing the connector 29, voice coil leadwires l2, l3 and conductor 14, and a means for heating the layer 31 ofsolder in the connector 29 to a temperature such that the solder willflow and insure the attainment of a good electrical connection. As shownin FIG. 7, the stranded conductor 14 is supported on a table 36 beneatha reciprocating cutter 37 carried by the rod 38 of a pneumatic cylinder39 supported on a not shown stationary frame. Then, as shown in FIG. 8,the cutter 37 is advanced to sever the connector 29, stranded conductor14, and voice coil lead wires l2, 13. As the cutter 37 severs theconnector 29, the tip of the cutter is received in a relieved area ll ofthe table and an electrode 42 compressively engages the connector 29 andurges the connector 29 against the electrically conductive worktable 36.Thereupon, a pulse of electrical energy is applied to a pair ofconductors $3,414 from a power means 46 and a pulse of electric currentflows through the conductors 43, 4-4, the electro '7 and table 36, andthe connector 29, the heating effect of which melts the layer of solder31 within the connector 29. Any well known and suitable electricalcontrol circuitry can be used as the power means 46 for supplying theelectrical energy to the electrode 42 and the table 36 which also servesas an electrode. As will be understood by persons skilled in the art,the power means is preferably provided with a manually operable switchor pushbutton for energizing the power means 46. The pulse of electricalenergy supplied by the power means 46 is preferably of sufficientmagnitude for a suflicient period of time to melt the layer of solder 31within the connector 29 without damaging the wires or conductortherewithin. When the layer of solder 31 liquifies, the connector 29acts as a capillary means and counteracts the capillary action of thestranded conductor l4 that would otherwise cause the molten I, solder toflow along the stranded conductor 14 away from the connector 29. In testsamples made according to the invention, it has been found that themolten solder actually flows toward the center of the connector 29 andthat the connector 29 operates as a capillary means and provides arepository for a mass of solder. Although FIGS. 7 and 3 illustrate theoperational sequence of substantially simultaneously severing andheating the malleable connector 29, it will be appreciated that theconnector 29, conductor l4, and voice coil lead wires 12, 13 could beheated prior to the severing step or at a substantially later period oftime. In addition, although a solder laminated connector has beenillustrated, a nonlaminated connector may be used and resistance weldedto the flexible conductor and voice coil lead wires.

After the severing operation has been performed, the voice coil assemblyappears substantially as shown in H6. 9 wherein portions 14a, 14b of thestranded conductor are connected to ends of the voice coil lead wiresl2, 13 by portions 29a, 29b of the connector 29, the portions 290 and 2%comprising separate and discrete malleable connectors. The completedvoice coil assembly of FIG. 9 is then assembled with other components toform a loudspeaker such as the loudspeaker 47 shown in FIG. wherein aframe 48 and magnet structure 49 are secured together with the voicecoil 10 cemented to a flexible spider 51 and suspended in an airgap 52in the magnet structure 49. A cone or diaphragm 53 is secured along theouter edge 53a thereof to the frame 48 and an edge 53b of an apertureformed near the center of the diaphragm is secured to the voice coil 10.The lead wires of the voice coil extend along a surface of the diaphragmand the stranded conductors connected thereto by the malleableconnectors extend through a small opening in the diaphragm and aresoldered to terminal such as the terminal 54 carried by the frame 48. Adust cap 56 covers the open end of the voice coil 10 in the assembledspeaker and prevents dust or other foreign material from entering theairgap of the magnet structure.

Although it is contemplated in the preferred embodiment of the inventionthat the connector include a layer of material such as solder, othertypes ofconnectors may also be used. One embodiment of a connector thatmay be used in lieu of connector 29 is the connector 57 illustrated inFIG. 11, with a serrated or roughened inner surface 58 for engaging thevoice coil lead wires and stranded conductor while being formedtherearound. When the connector 57 is used, any insulation coating onthe voice coil lead wires is readily broken and a good electricalconnection is easily attained between the voice coil lead wires and thestranded conductor. In addition it should be specifically noted thatwhen serrations on surface 58 are considered to be either undesirable orunnecessary, a relatively smooth inner surface may be provided on theconnector 57. Although a loudspeaker and components thereof have beendescribed herein for purposes of exemplification, it will be expresslyunderstood that the present invention may be utilized in many differenttypes of apparatus, including transducers, dynamoelectric machines,electromagnetic coils, relays, and any other apparatus wherein a pair oflead wires are to be connected to a pair of conductive leads.

While there has been illustrated and described what is at presentconsidered to be a preferred embodiment of the present invention, itwill be appreciated that numerous changes and modifications are likelyto occur to those skilled in the art, and it is intended in the appendedclaims to cover all those changes and modifications which fall withinthe true spirit and scope of the present invention.

We claim:

1. In a loudspeaker having a frame, a magnet structure supported by theframe and having an airgap associated therewith, a voice coil suspendedin the airgap and having first and second lead wires extendingtherefrom, a diaphragm connected to the voice coil, a pair of terminalssupported on the loudspeaker for electrically connecting the loudspeakerto an electrical circuit, a first discrete portion of a flexibleconductor connected between one of the terminals and the first leadwire, and a second discrete portion of said flexible conductor connectedbetween the other terminal and the second lead wire, the in i-'ovementcomprising a first discrete portion ofa malleable connector formedaround the juncture of the first lead wire with the first discreteportion of said flexible conductor, and a second discrete portion ofsaid malleable connector formed around the juncture of the second leadwire with the second discrete portion of said flexible conductor, saidfirst and second discrete portions of said malleable connector eachcomprising a severed section of a single assembled connector formedaround the lead wires and the flexible conductor.

2. The structure of claim 1, wherein the first and second flexibleconductors each comprise a plurality of strands of conductive material,the juncture of the first lead wire with the first flexible conductor isa connection reinforced with solder, the juncture of the second leadwire with the second flexible conductor is a connection reinforced withsolder, and the malleable connectors comprise capillary means forretaining the solder therewithin.

3. The structure of claim 1, wherein the juncture of the first lead wirewith the first flexible conductor is a connection reinforced by solder,the juncture of the second lead wire with the second flexible conductoris a connection reinforced by solder, and the malleable connectorscomprise capillary repositories for the solder at the junctures of thevoice coil lead wires with the flexible conductors.

d. A loudspeaker having a frame, a diaphragm supported for movementrelative to the frame, a magnet structure supported by the frame anddefining an airgap,'a voice coil having first and second voice coil leadwires, first and second terminals supported on the frame, a firstdiscrete portion of a flexible conductor connected to the first terminalat one end of said first discrete portion and to the first voice coillead wire at the other end of said first discrete portion, a seconddiscrete portion of said flexible conductor connected to the secondterminal at one end of said second discrete portion and to the secondvoice coil lead wire at the other end of said second discrete portion,the first and second discrete portions of said flexible conductor eachcomprising a plurality of strands of conductive material thereby tominimize the mechanical coupling between the diaphragm and the frame, afirst discrete portion of a malleable connector formed around thejuncture of the first discrete portion of said flexible conductor withthe first voice coil lead wire, and a second discrete portion of saidmalleable connector formed around the juncture of the second discreteportion of said flexible conductor with the second voice coil lead wire,said first and second discrete portions of said malleable connector eachcomprising a severed section of a single assembled connector formedaround the voice coil lead wires and the flexible conductor.

5. A method of connecting a pair of lead wires to conductive materialcomprising the steps of positioning the end portion of each of a pair oflead wires and a piece of conductive material adjacent to each other,securing a connector around the end portions of the lead wires and thepiece of conductive material, and severing the connector, lead wires,and piece of conductive material thereby to form a pair of separateleads each comprising a lead wire and a portion of the piece ofconductive material connected together by a portion of the connector.

6. The method of claim 5, wherein the connector includes a layer ofsolder and the step of securing the connector includes the step ofheating the connector thereby to melt the solder and reinforce theconnection between the lead wires and conductive material.

7. A voice coil assembly for an electromechanical transducer comprisinga bobbin, a length of magnet wire wound around the bobbin and havingfirst and second end portions, a first discrete portion of a piece ofstranded conductor joined at one end thereof to the first end portion ofthe magnet wire with a first discrete portion of a malleable connectortightly formed therearound, and a second discrete portion of said pieceof stranded conductor joined at one end thereof to the second endportion of the magnet wire with a second discrete portion of saidmalleable connector tightly formed therearound, said first and seconddiscrete portions of said malleable connector each comprising a severedsection of a single assembled connector formed around the end portionsand the stranded conductor.

8. The assembly of claim 7, wherein the first and second connectors eachcomprise a capillary repository for solder.

9. The assembly of claim 7, wherein the first and second connectors eachhave a roughened inner surface in engagement with the stranded conductorand end portions of the magnet Wife.

10. An assembly comprising a length of wire having first and second endportions, a first discrete portion of a piece of conductive materialjoined at one end thereof to the first end portion of the wire with afirst discrete portion of a connector tightly formed therearound, and asecond discrete portion of said piece of conductive material joined atone end thereof to the second end portion of the wire with a seconddiscrete portion of said connector tightly formed therearound, saidfirst and second discrete portions of the connector each comprising amalleable severed section of a single connector.

11. The assembly of claim 10, wherein the first and second discreteportions of said connector each comprise a capillary repository forsolder.

12. A voice coil connector assembly for a transducer comprising a voicecoil having first and second lead wires extending therefrom, a flexibleconductor, a portion of said lead wires being disposed along saidflexible conductor in electrical connection therewith, and a malleableconnector having opposite ends, said connector being formed around theflexible conductor and the portion of said lead wires, said lead wiresextending axially into the opposite ends of the connector, said leadwires and said conductor and said connector being adapted to be severedintermediate the ends of the connector to provide a pair of connectorportions each connecting a lead wire to a portion of the severedflexible conductor.

13. The assembly of claim 12 wherein said connector comprises acapillary repository and solder is disposed in said repository.

1. In a loudspeaker having a frame, a magnet structure supported by theframe and having an airgap associated therewith, a voice coil suspendedin the airgap and having first and second lead wires extendingtherefrom, a diaphragm connected to the voice coil, a pair of terminalssupported on the loudspeaker for electrically connecting the loudspeakerto an electrical circuit, a first discrete portion of a flexibleconductor connected between one of the terminals and the first leadwire, and a second discrete portion of said flexible conductor connectedbetween the other terminal and the second lead wire, the improvementcomprising a first discrete portion of a malleable connector formedaround the juncture of the first lead wire with the first discreteportion of said flexible conductor, and a second discrete portion ofsaid malleable connector formed around the juncture of the second leadwire with the second discrete portion of said flexible conductor, saidfirst and second discrete portions of said malleable connector eachcomprising a severed section of a single assembled connector formedaround the lead wires and the flexible conductor.
 2. The structure ofclaim 1, wherein the first and second flexible conductors each comprisea plurality of strands of conductive material, the juncture of the firstlead wire with the first flexible conductor is a connection reinforcedwith solder, the juncture of the second lead wire with the secondflexible conductor is a connection reinforced with solder, and themalleable connectors comprise capillary means for retaining the soldertherewithin.
 3. The structure of claim 1, wherein the juncture of thefirst lead wire with the first flexible conductor is a connectionreinforced by solder, the juncture of the second lead wire with thesecond flexible conductor is a connection reinforced by solder, and themalleablE connectors comprise capillary repositories for the solder atthe junctures of the voice coil lead wires with the flexible conductors.4. A loudspeaker having a frame, a diaphragm supported for movementrelative to the frame, a magnet structure supported by the frame anddefining an airgap, a voice coil having first and second voice coil leadwires, first and second terminals supported on the frame, a firstdiscrete portion of a flexible conductor connected to the first terminalat one end of said first discrete portion and to the first voice coillead wire at the other end of said first discrete portion, a seconddiscrete portion of said flexible conductor connected to the secondterminal at one end of said second discrete portion and to the secondvoice coil lead wire at the other end of said second discrete portion,the first and second discrete portions of said flexible conductor eachcomprising a plurality of strands of conductive material thereby tominimize the mechanical coupling between the diaphragm and the frame, afirst discrete portion of a malleable connector formed around thejuncture of the first discrete portion of said flexible conductor withthe first voice coil lead wire, and a second discrete portion of saidmalleable connector formed around the juncture of the second discreteportion of said flexible conductor with the second voice coil lead wire,said first and second discrete portions of said malleable connector eachcomprising a severed section of a single assembled connector formedaround the voice coil lead wires and the flexible conductor.
 5. A methodof connecting a pair of lead wires to conductive material comprising thesteps of positioning the end portion of each of a pair of lead wires anda piece of conductive material adjacent to each other, securing aconnector around the end portions of the lead wires and the piece ofconductive material, and severing the connector, lead wires, and pieceof conductive material thereby to form a pair of separate leads eachcomprising a lead wire and a portion of the piece of conductive materialconnected together by a portion of the connector.
 6. The method of claim5, wherein the connector includes a layer of solder and the step ofsecuring the connector includes the step of heating the connectorthereby to melt the solder and reinforce the connection between the leadwires and conductive material.
 7. A voice coil assembly for anelectromechanical transducer comprising a bobbin, a length of magnetwire wound around the bobbin and having first and second end portions, afirst discrete portion of a piece of stranded conductor joined at oneend thereof to the first end portion of the magnet wire with a firstdiscrete portion of a malleable connector tightly formed therearound,and a second discrete portion of said piece of stranded conductor joinedat one end thereof to the second end portion of the magnet wire with asecond discrete portion of said malleable connector tightly formedtherearound, said first and second discrete portions of said malleableconnector each comprising a severed section of a single assembledconnector formed around the end portions and the stranded conductor. 8.The assembly of claim 7, wherein the first and second connectors eachcomprise a capillary repository for solder.
 9. The assembly of claim 7,wherein the first and second connectors each have a roughened innersurface in engagement with the stranded conductor and end portions ofthe magnet wire.
 10. An assembly comprising a length of wire havingfirst and second end portions, a first discrete portion of a piece ofconductive material joined at one end thereof to the first end portionof the wire with a first discrete portion of a connector tightly formedtherearound, and a second discrete portion of said piece of conductivematerial joined at one end thereof to the second end portion of the wirewith a second discrete portion of said connector tightly formedtherearound, said first and second diScrete portions of the connectoreach comprising a malleable severed section of a single connector. 11.The assembly of claim 10, wherein the first and second discrete portionsof said connector each comprise a capillary repository for solder.
 12. Avoice coil connector assembly for a transducer comprising a voice coilhaving first and second lead wires extending therefrom, a flexibleconductor, a portion of said lead wires being disposed along saidflexible conductor in electrical connection therewith, and a malleableconnector having opposite ends, said connector being formed around theflexible conductor and the portion of said lead wires, said lead wiresextending axially into the opposite ends of the connector, said leadwires and said conductor and said connector being adapted to be severedintermediate the ends of the connector to provide a pair of connectorportions each connecting a lead wire to a portion of the severedflexible conductor.
 13. The assembly of claim 12 wherein said connectorcomprises a capillary repository and solder is disposed in saidrepository.